Building structure with alternating structural members and panels in compression



R. WATSON, JR BUILDING STRUCTURE WITH ALTERNATING STRUCTURAL MEMBERS 2Sheets$heet 1 Filed July 20, 1966 INVENTOR.

Aug. 20, 1968 R WATSON, JR 3,397,500

BUILDING STRUCTURE WITH ALTERNATING STRUCTURAL MEMBERS AND PANELS INCOMPRESSION Filed July 20, 1966 2 Sheets-Sheet 2 INVENTOR.

ROBERT WATSON, JR.

United States Patent BUILDING STRUCTURE WITH ALTERNATING STRUCTURALMEMBERS AND PANELS IN COMPRESSION Robert Watson, Jr., 57th and GarfieldSt., Hinsdale, Ill. 60521 Filed July 20, 1966, Ser. No. 566,579 4Claims. (Cl. 52-495) ABSTRACT OF THE DISCLOSURE An improved buildingstructure comprising alternating structural shapes and panels whereinthe panels are maintained under compression between the structuralshapes resulting in a wedging action between each junction of a paneland structural shape, forming a generally weathertight seal.

This invention relates to an improvement in building structures, andmore particularly to a novel structural assembly especially suitable forfloor, wall, and roof construction, and the method of assembly thereof.

Present day building structures generally either have load carrying beamand structural supports which are provided primarily for their loadsupport with the wall structure primarily considered for its enclosingfeatures, or panels which due to their over-all shape or elaborateinternal structure provide suitable load carrying characteristics andwhen a plurality of such units are structurally interlocked provide aload carrying wall system.

Present day construction methods require a large amount of on-the-sitefabrication of wall structures, and generally the erection ofscaffolding for the entire height of the structure. This is particularlytrue with conventional insulated double wall construction wherein thestructural framework is first erected, then girts, inner walls,sub-girts, insulation and finally the outer walls. Further, the abundantuse of fasteners creates leakage problems and sources for initiation ofdeterioration. Still further, the usual complex surfaces of many presentday building panels and materials do not lend themselves to the mostflexible utilization of modern materials and coatings. I

The present invention overcomes these problems by providing buildingstructures comprising a combination of structural shapes and panelswherein the panel is firmly held between two structural shapes by awedging action.

Another object of the invention is to provide a structural buildingassembly which greatly reduces the number of fastenings, girts, andsub-girts used in present building structures. A Still another object ofthis invention is to provide structural building components which mayefliciently utilize materials and coatings requiring non-formed flatpanel units.

Yet another object of the invention is to provide a building structurehaving great structural flexibility in the size of units and placementof doors, windows, etc.

Another object of this invention is to provide a novel structuresuitable for walls, floors and roofs.

Still another object is to provide a structural building assembly methodwhich requires a minimum of on-thesite erection labor and allowserection without the requirement of scaffolding, requiring access onlyto the bottom and top of the structure.

These and other objects and advantages of the invention will become moreapparent from the ensuing description and claims, when taken with theaccompanying drawings, in which:

FIGURE 1 is a cutaway perspective view of a portion of 3,397,500Patented Aug. 20, 1968 a structure embodying the principles of thepresent invention;

FIGURE 2 is a cross-section of a basically triangular structural shapein combination with a sandwich insulated construction panel according tothis invention;

FIGURE 3 is a crosssection of a basically triangular structural shape incombination with a spiral tube panel;

FIGURE 4 is a cross-section of a basically oval structural shape incombination with an insulated sandwich panel;

FIGURE 5 is a cross-section of a modified rectangulartriangularstructural shape in combination with a sandwich panel;

FIGURE 6 is a cross-section of a modified triangular structural shape incombination with a flush panel;

FIGURE 7 is a cross-section of a basically triangular structural shapein combination with a non-insulated single skin wall panel;

FIGURE 8 is a cross-section of an outside corner mullion assembly incombination with two sandwich panels at right angles;

FIGURE 9 is a cross-section of an inside corner mullion assembly incombination with two sandwich panels at right angles; and

FIGURE 10 is an isometric view illustrating use of a mullion as adownspout.

With particular reference to the drawings and in the first instance toFIGURE 1, the numeral 20 generally designates a wall structure definedby a course of plural panels 40 and alternating mullions 22 whichincorporate the principle of the invention. Wall structure 20 isillustrated as including corner assembly 23 which provides for panels 40on each side of it to extend at right angles to each other. As can begenerally observe-d from FIGURE 1, the building structure comprises aplurality of altern-ating structural shapes and panels, the structuralshapes defining an elongated, formed, load bearing element ofcross-section having opposing sides converging to an apex and a flangeextending laterally from each side of the apex, each of the flangesterminating with a leg extending toward the proximate of the opposingsides so as to exert a wedging action when a panel is maintained withone edge adjacent the proximate side in a plane approximately parallelto the flange and subject to a force directed toward the proximate side.The panels are maintained under a lateral compressive force due to theadjacent structural shapes being firmly secured from lateral movementwhile holding the panel in position under a lateral compressive force.It is readily observed that due to the angle of the side of thestructural shape, lateral force upon the panel forces the face of thepanel against the end of the leg of the shape directed toward that side,thus causing a wedging action. Thus, due to the wedging action of thecombination of the structural shape and panel, a generally weatherproofand rigid building structure may be obtained without the necessity offastenings to hold the panels in position. The same structure may beutilized for exterior walls, interior walls, floors, roofs, and interiorceilings. As may be seen in FIGURE 1, the load imparted to the panels,such as wind load in walls or vertical loading in floors or roofs, isdirectly transferred to the structural shape through the leg which restsfirmly against the panel as a result of the wedging action describedabove. The structural shapes may be of various cross sections,dimensions, gauge of material, and spacings to accommodate a widevariety of loading factors. Generally, spacing is from about 2 to 4feet, with 2 feet being preferred.

FIGURE 1 also illustrates window unit 24 as a part of wall structure 20.The window unit being of proper width and having vertical edges finishedin a similar manner as the panel is firmly held in place by the wedgingaction of the adjacent mullions 22. Any other desired unit such as adoor, louver, translucent panel sections, etc. may be utilized in likefashion. The flexibility of this building structure is especiallyapparent when combinations of different units are utilized and thepanels are simply cut to appropriate lengths without the necessity ofany further structural framing and flashing. Frame for any of the aboveunits also may be Welded into the assembly thus eliminating the need forstructural framing and flashing.

As shown in FIGURE 1, wall structure may be mounted on supporting wall28 of any suitable design and of any desired height. For example, wallstructure 20 may be mounted on concrete footings or may be mounted atopa masonry wall, or atop a wall of any suitable building material,adapted so that the lower ends of the mullions 22 and corner assembly 23are firmly secured in position. The mullions may, for example, be set ina suitable angle 25 or on any appropriate shape and fastened firmlythereto by any suitable means such as clipping, bolting, riveting orwelding, etc. The upper ends of mullions 22 and corner assembly arefirmly held from movement by any appropriate means such as clipping,bolting, riveting or welding to any appropriate structure such aschannel 26 on the inside wall structure 20. Alternatively, the framingstructure may be positioned atop the wall or along the exterior at thetop of the wall structure. It is to be noted that the structure at theupper terminus of wall structure 20 may be readily adapted toaccommodate any style of roof such as flat or pitched.

FIGURE 1 also illustrates an embodiment of a roof deck structureaccording to this invention and generally referred to as 85. Roof beams80 are firmly secured at the ends to channel 26 and roof panel 60 isfirmly held without fastenings in a generally weatherproof fashionbetween roof beams 80 by the same wedging action described in referenceto the wall structure. Additional transverse roof joists may span thebuilding at any spacing interval beneath beams 80 to accommodate a widevariety of loading requirements. The exterior roof surface is generallysmooth to accept any conventional surfacing material such as tar andgravel, or on pitched roofs the joints can be sealed by an appropriatemeans and the surface left exposed.

Each of the panels 40 is formed by sandwich construction having innerand outer walls of sheet material such as steel, aluminum or plasticwhich is bonded to an inner core of closed cellular foam insulatingmaterial such as polyurethane, polystyrene, etc. Such panels provideexcellent insulating qualities and enable different materials to beutilized on each side of the panel. Further, such panels may be entirelyfinished at the point of manufacture since no panel fastenings areutilized. Due to their smooth surface and lack of fastenings, the wallsof the panels are especially well suited to plastic coatings whichrequire factory application.

To further illustrate specific embodiments of the invention, attentionis directed to FIGURES 2 through 9 each of which shows a cross sectionof the combination of a structural shape and panel according to thisinvention.

FIGURE 2 shows an enlarged cross section detail of the wall structureshown in FIGURE 1. Specifically, the structural shape generally referredto as 30 is triangular shape having first side 31 and second side 32,sides 31 and 32 being opposing sides, converging to apex 33 and flanges34 and 35 extending from each side of apex 33 parallel to third side 36of the triangle, each of flanges 34 and 35 terminating with legs 37 and38 respectively, extending toward the proximate of opposing sides 31 and32. The panel generally referred to as 40 is a sandwichtype panel havingouter surface 41 and inner surface 42 which are preferably plastic ormetal such as steel or aluminum bonded to central core 43 which ispreferably a closed cell synthetic foam such as polyurethane orpolystyrene. The panel of this construction is extremely rigid and willnot deform from the lateral compression to which the panel of thisstructure is subjected. Edge 44 of panel 40 adjacent side 31 ofstructural shape 30 is preferably shaped to fit the contour of side 31and may have the core 43 slightly extended beyond the ends of surfaces41 and 42, and the end of outer surface 44 adjacent side 31 may havecompressible Weather seal 45 applied along its length. In any case, thecontact of edge 44 with side 31 is such as to form a generallyweatherproof seal along the entire length as a result of the wedgingaction obtained by the combination of forces between leg 37 and panelsurface 42 and side 31 and panel edge 44 when a force is applied topanel 40 toward structural shape 30. It is readily seen that panel 40does not afford thermal transference continuity between exterior side 41and interior side 42, thus rendering a panel structure having very lowthermal conductivity. As illustrated, legs 37 and 38 make an acute anglewith flanges 34 and 35 respectively thus enabling plastic condensationmolding 39 to snap into a firmly held position covering the entiresurface of structural shape 30 which is exposed to the interior of thestructure. Such a condensation molding on the interior of the metalstructural shape is effective to lower thermal conductivity and therebysubstantially reduce the formation of condensation. Utilizing thestructure shown in FIGURE 2, the entire inner surface of the structuralwall or roof may be thermally insulated from the outer surface.

FIGURE 3 illustrates a specific embodiment of the invention utilizing aspiral tube panel which may be filled with loose wool-type insulationmaterial or a synthetic closed cell foam material. When utilizing apanel having an end shape which does not conform to the adjacent surfaceof the structural shape, compression pad 50 of compressible materialhaving side 51 to conform to the shape of the end of the panel andopposite side 52 to conform to the surface of the structural shape maybe placed along the entire length of the juncture to assure a generallyweatherproof seal.

FIGURES 4 and 5 illustrate other specific embodiments of the inventionwhich utilize different structural shapes to obtain the same wedgingaction between the structural shape and a panel to achieve the objectsof the invention set forth above. Obviously, many different structuralshapes are suitable in the building structure of the invention.

FIGURE 6 shows a detail cross section of the roof structure illustratedin FIGURE 1. Legs 87 and 88 of structural shape are extended to asuitable length so that surface 61 of panel 60 is approximately flushwith side 86 of structural shape 80 and the panel is firmly retainedbetween the structural shapes by the wedging action described above.This embodiment results in a structure having one smooth surface and isespecially suitable for floor and roof construction. Panel 80 maysuitably be a structural panel such as plywood or precast concrete.Conventional roofing materials are then readily applied over the smoothsurface afforded by this structure, if desired.

FIGURE 7 illustrates a specific embodiment of this invention utilizing asingle wall panel such as plastic or metal such as steel or aluminum.

FIGURE 8 illustrates an enlarged cross section of the corner assemblygenerally referred to as 23 in FIGURE 1. It is seen that structuralshapes 24 and 25 are longitudinal halves of the typical mullion sectionas shown in FIGURE 2 arranged so that panels 40 are at right angles toeach other. Of course, it is obvious that by use the two separatestructural shapes 24 and 25, two panels may be held at any angle from 0to to each other to form an outside corner by modifying the cornerflashing 26. Corner flashing 26 may be held in place by welding orsimply by the wedging action. This permits extreme flexibility inbuilding construction with a minimum of specialized components.

FIGURE 9 shows an inside corner according to this invention. Thestructural shape generally referred to as 27 is a standard mullion asshown in detail in FIGURE 2 wherein said third side of the triangle isbent at 28 to form a 90 angle and thus hold panels 40 at a 90 angle. Ofcourse, the mullion may be bent to any desired angle to form the insidecorner as required. The space between the flanges separated by suchbending may be covered by any type of flashing desired.

The structural shapes used in the invention may be fabricated by rollforming from sheet metal of about 10 to 18 guage. If desired, somestructural shapes may be filled with concrete as required to extendtheir load capacities and span range. The plurality of generally hollowshapes throughout the building structure permits great flexibility inproviding ducts to accommodate piping, wiring, and other utilities. Forexample, as shown in FIG- URE 10, when structural shape 30 is used as amullion it may be sealed to render it water-tight and gutter 70 may bemounted directly atop the wall structure so that openings from thegutter will lead water into mullions as desired, thus providing integralvertical downspouts.

The erection method of this invention requiring minimum on-the-sitelabor is especially unique. The structure may be erected by firmlysecuring each end of a first structural shape against lateral movement;holding a full length panel or composite of panel sections, windows,etc. in position with a first edge adjacent to the secured structuralshape; placing a second structural shape into position adjacent thesecond edge of said panel opposite said first edge, applying a force tosaid second shape toward said first shape to impart a laterallycompressive force to the panel and causing a wedging action on oppositeedges of the panel by the first and second shapes; and while applyingsaid force firmly securing each end of said second shape against lateralmovement. Thus, in wall erection, a mullion may be rigidly positioned,then a panel set in place, the next adjacent mullion roughly positionedand pulled toward the rigid mullion by any suitable means such as chainjacks located near the top and bottom to impart a lateral compressiveforce to the panel causing the panel to become positioned due to thewedging action, and then fastening the second mullion.

A minimum of skeletal structure is necessary in the building structureof this invention; only that which is necessary to provide for firmsecuring of the ends of the structural shapes and for additionalstructural reinforcement as may be necessary in floor and roofconstruction. Thus, even for insulated wall construction, scatfolding isnot generally required since erection of the finished wall panelrequires access only at the top and bottom. Additional stifieners suchas girts are not generally required, and sub-girts are never required.

Structures coming within the invention provide architecturally pleasingwall structures, both interior and exterior, and etficient andeconomical floors and roof decks. Those skilled in the art will readilyappreciate the versatility provided by the structure of this inventionand the simplicity and economies afforded by the erection method.

While certain operative forms of the invention have been shown anddescribed, it should be understood that these showings and descriptionsshould be taken in an illustrative or diagrammatic sense only. There aremany modifications in and to the invention which will fall within thescope and spirit thereof and will be apparent to those skilled in theart. The scope of the invention should be limited only by the scope ofthe hereinafter appended claims.

I claim:

1. In a building structure comprising a plurality of alternatingstructural shapes and panels, the combination of a spaced first andsecond structural shape defining an elongated, formed element of crosssection of opposing sides converging to an apex and flanges extendinglaterally in approximately opposite directions from each side of saidapex, each of said flanges terminating with a straight leg extendingtoward the proximate of said opposing sides with the terminal ends ofsaid legs in spaced relationship to said sides; and a panel connectingsaid shapes in a plane approximately parallel to said flange of saidfirst and second shape and lying within planes defined by connectingextremities of said first and second shape, said panel having a firstedge against said proximate side of said first shape and an oppositesecond edge against said proximate side of said second shape, and a faceagainst said terminal end of a leg of said first and second shape; saidpanel maintained in compression between said first and second shape,forcing the face of said panel against said terminal ends in a wedgingaction to form a generally weather-tight seal between the terminal endsof the legs and the face of the panel and between the end of the paneland the adjacent side of the structural shape.

2. The structure of claim 1 wherein said structural shapes are mullions.I 3. The structure of claim 1 wherein said structural shapes aretriangular shape having opposing sides converging to an apex and aflange extending laterally from each side of said apex parallel to thethird side of said triangle.

4. The structure of claim 1 wherein said structural shapes aretriangular shape having opposing sides converging to an apex and aflange extending laterally from each side of said apex parallel to thethird side of said triangle, said leg being of a length to hold saidpanel approximately flush with said third side.

References Cited UNITED STATES PATENTS 619,968 2/1899 Leonard 524951,865,674 7/1932 Carter 52470 X 2,040,578 5/1936 Ve'nzie 52228 X2,053,843 9/1936 Rossi 52496 X 2,169,253 8/1939 Kotrbaty 52497 FRANK L.ABBOTT, Primary Examiner.

ALFRED C. PERHAM, Assistant Examiner.

